Process for making phonograph-records.



J. W. AYLSWORTH. PROCESS FOR MAKING PHONOGRAPH RECORDS. APBLIOATIQNFILED SEPT. 7,1912.

1,1 10,4;17. v Patented Sept. 15, 191$ fijzizgsses: [2366 25 JAM f i -7fi); JZZQ- V UNITED STATES PATENT oFmoE,

JONAS w. AYLs wonTn, or

EAST ORANGE, -NEW' JlERSEY, ASSIGNOB, BY MESNE ASSIGNMERTS, '.l' O NEWJERSEY PATENT COIPANY, OF WEST ORAN E, NEW

JERSEY, A CORPORATION OF JERSEY. i

rnocns's ron MAKING rnonoenara-nnconns.

T '0 all 1011 m it may concern. a

Be it known that 1, Jonas W. AYLswoRn-i,

a citizen of the United States, and a resi' dent of East Orange, Essexcounty, New

7 Jersey, have made a certain new. and useful Invention in Processes forMaking Phonograph-Records, of which the following is a description.

This invention relates to a process of producing phonograph records,this application beinga division of my application, Serial made solid orbacked with solid material.

' The result above referred to is preferably I accomplished by castingin a rotating mold a composition containing ingredients which cause thesame tpfoam copiously or evolve gases during theformation of the recordto cause the same to be spongy and porous,

while the outer record surface of the same which is in contact with themold will be free from bubbles and similar defects. More specifically,my invention is accomplished by casting in the manner referred to :1rec- 0rd of a composition, the ingredients of which react on suflicientapplication of heat to form a hard infilsible condensation prod uct. Inmy present invention, a composition of this character is made'use of inwhich the ingredients are so chosen and proportioned as to causeexcessive foaming or the evolution of dissociationgases during thetransition ofthe material from the molten plastic state to a solidplastic or nonplastic state, the product, caused by the evolution ofsuch gases, being"porous. and

spongy throughout its mass, while the'-rec-' ord surface-thereof issmooth and from bubbles. v V t Y Y @A composition such asthat describedmay be made by adding anexcess of'paraformah dehyde, diortri-loxyinethylene, or othersuitable aldehyde to a composition having-a1formula such as Formula N01 If-in mya "plication No. 496.060QEOISPIaStiKLQOlIIPOSIfiOIl';

Specification of Letters Patent. Patented Sept. 15, 1914.1

Original application filed my 25, 1909, Serial 1V0. 498,357. Divided and1912. Serial No. 719,094.

this application filed September 7,

and process of manufacturing the same,

May 14,1909; The formula referred to is 1 Phenol resin 10o risbPolymerized lonnaldehyde...'...'. 51:0 7" light. Benzoic anhydrid 5to10formed in a thin layer of material free from poros1ty. The thickness ofsuch layer may be controlled at will by pouring in the mold first anamount of a mass so constituted that it will not foam while changingfrom the molten plastic to a non-plastic or a solid condition,subsequently pouring in the mold the mass which is designed to foam orevolve dissociation gases whereby the porous backing or body of therecord is formedi I Attention is hereby directed to the accompanyingdrawings, forming part of specification, in which; I

Figure 1 represents a longitudinal section through a record made inaccordance with my invention, and Fig. 2 is a longitudinal sectionthrough a similar record formed with bearing rings and shown mounted onI the taper mandrel which is shown in dotted Referring to the drawings,the recordl lines.

is formed having a smooth hard non-porous outer surface 221ml :1

of this character is shown mounted on the porous spongy back-I ing orbody portion3. -In.Fig. 2, a. record taper mandrel' t, the record being.formed with 'suitable bearing rings 5 and :6.- A rec- .ord similar tothat disclosed in Fig. 2 may be formed by casting'the' record materialin a rota'ting 'mold in which bearing ring .of hard rubber or' othersuitable material or of the final condensation product of a res-f inizedphenol have been secured in position previous -to the pour-ingot therecord, in

the manner disclosedin myappl" i n No. 4939 fil da ra 29, .1909.-

As is well known, the reaction between a phenol and an aldehyde isaccompanied by the evolution of dissociation gases unless acounteracting pressure is employed. In the case. of the processdescribed and claimed in this application, the speed of rotation of themold is insufiicient to generate a counteracting pressure due to thecentrifugal action sufficient to counteract the evolution of gases withsubstances in the roportions used. In the formula above re erred'to asFormula No. 1 in my application No.' 96,060, a certain proportion ofbenzoic ancold. This material or materials having similar properties, asdescribed in my above mentioned application, may be used or not asdesired, 1n the spon record composition here described an claimed.

The benzoic anhydrid in addition to being a final product solventelement is also a water combining element, as described in myapplication Serial No. 496,060 referred to, that is, it has theproperties of combining during the reaction with any traces of waterwhich maybe contained in the substance. An' other substance, such asvarious anhydri s or organic acids, may be used as an ingredient in thecomposition, to perform the same function if desired. Also it is to beunderstood that I am not limited to the substances in proportionsreferred to in the above entioned formula,

but that various combinations of phenols or phenolic substances andaldehydes or other substances containing the methylene radical CH invarious proportions maybe used with good results so long as theproportion of aldehyde or methylene containing substance is sufiicientto cause the copious evolution of ases in the mass during the formationof t e record at the speed of rotation necessary to form .the record.

While I have described my invention specifically in connection withphenol condensation products,'it is-to be understood that I am notnecessarily limited theretof For exan'iple,'a celluloid record may beformed having the general characteristics of my mvention. In practisingthe invention with this substance, a thin film' of celluloid is firstformedon the bore of the record from a suitable solution by evaporatingaway the I solution to form-a non-porous outer surface for the recordcylinder. A further solution of celluloid is then introduced into therotat- .ing mold and evaporation carried on 'more quickly than in theformation of the outer film, to cause foaming of the substance duringtheevaporation and the consequent formation of the spongy celluloid body orbacking.

Having now described my invention, what I claim and desire to protect byLetters Patent is as follows: i

1'. The process of molding sound records which comprises forming asmooth nonporous surface portion in contact with the surface of a moldand forming a spongy porous backing or body forsaid surface by causingthe material forsaid backing or body to harden while causing the same tofoam copiously, substantially as described.

2. The process'of molding sound records which comprises'forming a smoothnonporous surface portion from fluid material in contact, with thesurface of a rotating mold and forming a spongy porous backing or bodyfor said surface portionby causing the material for said backing or bodyto harden while causing the same to foam copiously during the rotationof the mold, substantially as described.

3. The process of molding sound records, consisting in introducing intoa mold substances which react on application of heat toform an infusiblecondensation product, supplying heat sufiicient .to cause the reactionto ensue to form a record having a smooth non-porous record surface, andren- 'deringthe backing of the record porous by the copious evolution ofdissociation gases, substantially as described.

4.- The process of molding sound records.

'solvent element with more than sufiicient.

aldehyde to combine therewith without evolution ofgas, and heating thesame in a rotating mold to form centrifugally without a counteractingpressure, a record having a smooth outer surface while rendering thebody of the record porous by the evolution of gases, substantially asdescribed.

6. The process of molding sound records, consisting in forming ceiitrifually a record surface layer of a phenol-aldjiyde condensationpr'oduot'on the bore, of a rotating mold, causing the reactionbetween'the comonentstoensue in.situ to form a hard inusible finalcondensation product without the evolution of dissociation gases in saidlayer and forming on the bore of the saidspongy material, substantiallyas described.

7. The process of molding sound records which comprises introducing intoa. suitable mold a phenolic substance and more than suflicient methylenecontaining substances to combine therewith without evolution of gas andheatin of said substances to form a hardened infusible condensationproduct and to cause the copious evolution of disso- 'ciation gases,substantially as described.

8 The process of moldlng sound records which comprises introducing intoa suitable mold a phenolic substance and more than sufficient methylenecontaining substances to combine therewith without evolution of gas,rotating the mold, and heating said substances to form a hardenedinfusible condensation product and to. cause the copious evolution ofdissociation as described. v

This' specification signed and witnessed this 4 day of Sept., 1912.

JONAS W. AYLSWORTH. Witnesses:

FREDERICK Bncnmun, MARY J. Lunmw.

gases, substantially

